System and method for handling printing press workload

ABSTRACT

A system and method is provided for ganging print orders to be printed on a press based on a set of print attributes, wherein associated digital files of the print orders are ganged together in one file location to generate a gang ticket in a database for the ganged print order, and displaying the gang ticket.

FIELD OF THE INVENTION

The present invention relates generally to a system and method for dynamically determining and handling printing press workload, and more particularly, to a system and method for distributing print order workload to internal presses or external partners' presses based on the current calculated press workload, and efficiently combining multiple press-ready orders based on the orders' print specifications/attributes.

BACKGROUND OF THE INVENTION

In the commercial printing industry, customers design and order many diverse formats, sizes and quantities of documents for printing to suit their advertising or other needs. These include everything from smaller-sized business cards, post-cards and mail inserts, to multiple-page catalogs and larger-sized products such as posters. The printer often must convert customers' submitted digital files into press-ready files that can print on any commercial printing press. Accordingly, it is desirable for a printer to combine multiple press-ready files for smaller-sized documents of different formats onto one larger-sized press sheet, in order to minimize paper waste and increase press efficiency to maximize profitability.

Also, customers request various production speeds for their products, or “turnaround” time, usually anywhere between 2 days to 2 weeks. The printer, therefore, needs to be able to schedule or distribute printing to its presses and combine orders onto press sheets in such a way that each of those individual customer orders' turnaround time is met, while utilizing press resources as efficiently as possible.

Once the orders are combined, the press operators need to be able to track the group of combined orders, called a “gang,” through their workflow. When using a database workflow system, it is beneficial for the operator to be able to view and track the gang as a single press job while having the ability to view the specific details of the individual orders.

SUMMARY OF THE INVENTION

The present invention provides a system and method of dynamically handling press workload, including determining current press workload, distributing new print orders and their associated digital files to internal presses and/or external partner's presses based on the current press workload, and efficiently combining multiple press-ready orders based on the orders' print specifications/attributes.

In one embodiment of the present invention, the method includes: dynamically determining current press workload; and distributing new print orders and their associated digital press-ready files to an internal press or external partner based on the current workload and based on a set of print attributes, such as the turnaround time for each of the print orders, in order to maximize press resources.

Still in one embodiment of the present invention, the method includes: determining which print orders can be printed or “ganged” together on the same press sheet based on a set of print order attributes; and collecting the press-ready files corresponding to the print orders together in one file location for combining onto a single press sheet.

Further in one embodiment of the present invention, the set of print order attributes for the ganged orders include but are not limited to: total and component quantities to be printed for each order, the product dimensions, the type of paper to be used, whether both front and back will be printed and the number of color inks to use on each side, whether coating will be applied, and required print completion date.

One of the advantages of the present invention is that the dynamic press workload and print order distribution system allows for efficient scheduling and distribution of print orders, which results in the ability to meet the customers' requested turnaround time for the orders and allows for efficient use of commercial printing press capacity and resources.

Another advantage of the present invention is that the print order ganging system allows operators to easily assign multiple press orders together to be combined on a single gang, in such a way to minimize paper waste and increase efficiency to maximize profitability.

A further advantage of the present invention of the print order ganging system is that it collects the files together in one location for combining onto a press sheet, and combines the orders together in a print order database on one unified work order, called a “gang ticket” which lists all the ganged orders for handling through the press workflow, while allowing operators to view specific details of each individual order on the gang.

These and other features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, wherein it is shown and described through illustrative embodiments of the invention, including best modes contemplated for carrying out the invention. As it will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed descriptions that follow are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a flowchart of an exemplary process of handling printing press workload, in accordance with the principles of the present invention.

FIG. 2 illustrates a screen display of a press workload dashboard with estimated times calculated for each press run, in accordance with the principles of the present invention.

FIG. 3A illustrates a screen display of a press workload production schedule summary for all internal presses, showing the number of press runs and estimated press time by print date for each press, in accordance with the principles of the present invention.

FIG. 3B illustrates a screen display of a press workload production schedule summary showing the current workload of two main presses in number of hours each press is ahead or behind schedule, including a dynamic color-coded line graph, in accordance with the principles of the present invention.

FIG. 4 illustrates a flow chart of one exemplary process of assigning multiple print orders to be printed together on a single gang, and automatically collecting the files for those orders into one file location and combining the orders for the gang onto a single database gang “ticket” (or work order), in accordance with the principles of the present invention.

FIG. 5 illustrates screen displays for one exemplary process of selecting and assigning multiple print orders to a single gang in accordance with the principles of the present invention.

FIG. 6 illustrates a single digital press-ready file for a gang, the creation of which is simplified through the automatic collection of the individual files in one file location, in accordance with the principles of the present invention.

FIG. 7 illustrates a single gang “ticket” or work order for a press workflow database system that includes multiple types of print orders combined onto one press sheet, in accordance with the principles of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention provides a system and method of handling printing press workload, from the distribution of the print orders to certain presses based on dynamically determining the current press workload, through the efficient combining of multiple orders together based on a set of print specification/attributes.

FIG. 1 illustrates one exemplary process 100 of handling press workload. The process 100 starts with an operation 102 of receiving a plurality of print orders that have been processed and are ready to be printed on press. In an operation 104, the process 100 allows an automated system and/or a coordinating reviewer to determine whether to print each order on an internal press or at an external partner's press based on, for example, the current internal press workload.

In an operation 108 shown in FIG. 1, orders distributed to internal presses are either assigned to a specific press, or set to wait for assignment to a gang to be combined with other print orders on a press sheet for a particular press. Once a group of orders are assigned to a gang, in an operation 112, the process 100 automatically collects the digital files from multiple individual file locations and deposits them to a single gang file location. With the files together in one location, an operator can more easily combine the files onto a single press sheet file. In addition, operation 112 also automatically combines the information for the individual orders onto a single gang ticket for efficient tracking of the combined orders through a press database workflow.

It is appreciated that the above process 100 may be varied depending on the customer needs within the scope or spirit of the present invention.

In FIG. 2, a screen display of a component of a press workload schedule dashboard or monitor of one embodiment of a press workload handling system 200 is shown. On the press workload dashboard, it is shown that twenty-one (21) press runs are scheduled to be printed on the 5-color press (abbreviated as 5C) on Jun. 29, 2005. A press run generally refers to one set of ink and/or coating impressions made on one side of paper that's run through the press.

Columns of the dashboard shown in FIG. 2 show items such as: up and down “Move” buttons for moving a print run earlier or later in the sequence; “Order Number/Gang” showing an order number or a gang number which contains a group of print orders; and several print attributes for the order or gang, such as inks, coating and paper to be used. Since one print order or gang of orders may involve multiple press runs (if there will be printing on two sides, for instance), there may be more than one press run for an order or gang on the dashboard.

Another column in FIG. 2 titled “Estimated Time” shows the calculated time in hours for the press to complete a print run, which is based on the number of Impressions (abbreviated as Impr) to be print and other print attributes for the order or gang of orders.

As shown in FIG. 2, by displaying the print orders and gangs, print status, and the characteristics of the print orders for a given press, and also allowing the print orders to be moved in the scheduled sequence, the press workload schedule can be dynamically changed and monitored. By estimating the time for each print run, the press workload handling system can dynamically display the number of hours of printing scheduled per day per press, as evidenced in the next drawing.

It is appreciated that the press workload schedule dashboard in FIG. 2 may also display other suitable items to be monitored without departing from the scope of the present invention.

In FIG. 3A, a screen display of a print press operation production dashboard or monitor of one embodiment of a press workload handling system 300 is shown. A top display 302 shows items such as the number of orders, total value of the orders, the average number of orders, and the average value of the orders that are under review by a print order coordinator for external partners, under review by an internal production coordinator, under a to-be-assigned gang waiting list, under an assigned gang number, or assigned under different printing presses (e.g. DI, 5C, 1C, etc.).

A middle display 304 in FIG. 3A shows the “Must Print By” week schedules (e.g. from Sunday 6/26 to Sat 7/2) for different presses, noted by abbreviations (e.g. DI, 5C, 2C and 1C). The series of numbers shown for each Must Print By day for each press represent the estimated calculated press workload for the orders scheduled to print that day. A key for the series is given at the bottom of FIG. 3A: each series of numbers shows the Number of Press Runs/Estimated Press Time/Press Load Goal/Adjusted Press Load.

A bottom display 306 in FIG. 3A shows actual weekly production (e.g. from Tues. 6/21 to Sun. 6/26) of different presses, e.g. DI, 5C, and 1C, including actual calculated press time.

FIG. 3B shows a screen display of color-coded line graphs indicating the calculated printing press workload for two internal presses, the DI and 5C presses. The graphs show the number of hours each press is ahead or behind schedule. As shown in FIG. 3B, the DI press was 7.5 hours ahead of schedule and the 5C press was 6.1 hours ahead. In both cases the bar on the graph shows the presses to be in the green zone (the color is not shown) of the graph, indicating they are on schedule or less than 8 hours ahead or behind. The hours are calculated based on the estimated press workload hours calculated and shown in the display 304 of FIG. 3A.

An advantage of the system 300 of the present invention is that it allows print order production coordinators to quickly determine whether to distribute print orders to internal presses or external partner presses based on the current workload of the internal presses, so that no press is overloaded or lacking enough work to fill its capacity, and orders can meet the customer's requested timelines.

It is appreciated that the production dashboard components in FIGS. 3A and 3B may also display other suitable items to be monitored or vary in color or scale without departing from the scope of the present invention.

FIG. 4 illustrates one exemplary process 400 of handling press workload for a print order ganging system. The system allows an operator to combine a variety of different types of print orders onto gangs in accordance with the principles of the present invention. The process 400 starts with an operation 402 of viewing a list of a plurality of print orders that have been distributed for internal presses and are waiting for assignment to a gang, to be combined with other orders on a press sheet. In an operation 404, the process 400 allows an operator to determine and select which print orders can be printed together on the same press sheet based on a set of print order attributes. In an operation 406, the process 400 assigns the multiple orders to either a new or existing gang which is assigned to a particular press for printing.

FIG. 5 illustrates one embodiment of a print order ganging system 500 of a press workload handling system, in accordance with the principles of the present invention. The print order ganging system 500 allows an operator to view a list of print orders and their print attributes in screen displays 502, 504. The print orders may include a wide variety of product types, quantity of pieces ordered, number of color inks and printed sides requested, and different shipping speeds requested. Specific comments entered for the individual orders are also displayed. The system 502 displays the date each order must print by and the date each order must ship by, which are automatically calculated based on the production speed (turnaround time) requested by the customer. The production speed equals the number of business days within which the order must be printed.

The print order ganging system 500, as shown in the screen display 502, allows an operator to check a box next to each print order that the operator determines should be assigned together to a gang, either assigned to a new gang or to an existing gang. The operator then assigns the new or existing gang to a particular press where the ganged print order files are printed by the listed Must Print By date. The display also includes thumbnail images of each of the ganged print order files to aid the operator in selecting files with similar ink densities and other qualities for optimal press efficiency.

As shown in the screen display 504, once the operator has selected the multiple files to be ganged together, the system 500 allows the operator to assign the ganged print orders to a new gang by choosing ‘New”, or add orders to an existing gang by using the “Choose Gang” drop-down list/menu to choose an existing gang number.

An advantage of the print order ganging system 500 is that it allows an operator to sort by any of the column, headings to more easily view orders with similar attributes. For example, if the operator is building a new gang or adding to an existing gang to be printed on 100# Uncoated Cover paper, the operator can simply click on the column heading ‘Type of Stock’ to sort by that attribute and view all the orders with that paper type together.

Another advantage of the present invention is that it allows a wide variety of file formats or different types of print orders to be ganged on the same press sheet and be printed on a commercial printing press to satisfy a wide variety of customers' needs. The ganging technique also allows for efficient management of press workload, thereby resulting in quick turnaround time and efficient use of commercial printing press resources.

It is appreciated that the print order gang assignment screen displays in FIG. 5 may also include other suitable items to be monitored without departing from the scope of the present invention.

Once the operator clicks the button “Assign To Gang” as shown in the screen display 504, the system 500 automatically combines the press-ready digital files into one file location. This significantly saves the operator time and minimizes errors in later combining the files into a single press-ready file for a single press sheet.

FIG. 6 shows an example of a single digital file which contains the files that are collected and deposited into one location for facilitating gang creation in the print order ganging system, in accordance with the present invention.

In addition to collecting the digital files, the print order ganging system automatically combines information and images for each of the individual print orders in a database workflow for a gang ticket. FIG. 7 is a screen display of an exemplary gang ticket, which displays the order numbers, attributes and thumbnail images for each of the ganged print orders. An operator may click on an order number on the gang ticket to view more details and attributes about the individual order than are displayed on the gang ticket. At the top right of the display on FIG. 7 is a link for Gang Files which are previously collected together into one file location. An operator may click this link to view the press-ready files if needed for more detailed quality control check.

It is appreciated that the gang ticket illustrated in FIG. 7 may also display other suitable items to be monitored without departing from the scope of the present invention.

From the above description and drawings, it will be understood by those of ordinary skill in the art that the particular embodiments shown and described are for purposes of illustration only and are not intended to limit the scope of the present invention. Those of ordinary skill in the art will recognize that the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. References to details of particular embodiments are not intended to limit the scope of the invention. 

1. A method of handling press workload, comprising: receiving a plurality of print orders, each having a set of print attributes and an associated digital file; ganging the print orders based on the set of print attributes; automatically collecting the digital files for the ganged print orders together in one file location; and generating a gang ticket in a database for the ganged print orders and displaying the gang ticket.
 2. The method of claim 1, wherein the gang ticket includes different file formats.
 3. The method of claim 1, wherein the gang ticket includes different file characteristics.
 4. The method of claim 1, wherein the set of print attributes include total quantity of the print orders, incremental quantities of component parts of the print orders, required turn around time, and/or estimated print completion time.
 5. A method of handling press workload, comprising: receiving a print order which has a set of print attributes and an associated digital file; assigning the print order to a gang to be printed on a press based on the set of print attributes; automatically collecting the digital file of the print order together with corresponding digital files of the gang in one file location; and generating a gang ticket in a database for the ganged print order and displaying the gang ticket.
 6. The method of claim 5, wherein the gang ticket includes different file formats.
 7. The method of claim 5, wherein the gang ticket includes different file characteristics.
 8. The method of claim 5, wherein the set of print attributes include total quantity of the print order, incremental quantities of component parts of the print order, required turn around time, and/or estimated print completion time.
 9. A system for handling press workload, comprising: a print order receiving module that receives a plurality of print orders, each having a set of print attributes and an associated digital file; means for ganging the print orders based on the set of print attributes; and means for automatically collecting the digital files for the ganged print orders together in one file location, generating a gang ticket in a database for the ganged print orders, and displaying the gang ticket.
 10. The system of claim 9, wherein the gang ticket includes different file formats.
 11. The system of claim 9, wherein the gang ticket includes different file characteristics.
 12. The system of claim 9, wherein the set of print attributes include total quantity of the print orders, incremental quantities of component parts of the print orders, required turn around time, and/or estimated print completion time.
 13. A system for handling press workload, comprising: a print order receiving module that receives a print order which has a set of print attributes and an associated digital file; means for ganging the print order to be printed on a press based on the set of print attributes; means for automatically collecting the digital file of the print order together with corresponding digital files of the gang in one file location, generating a gang ticket in a database for the ganged print order, and displaying the gang ticket.
 14. The system of claim 13, wherein the gang ticket includes different product formats.
 15. The system of claim 13, wherein the gang ticket includes different product characteristics.
 16. The system of claim 13, wherein the set of print attributes include total quantity of the print order, incremental quantities of component parts of the print order, required turn around time, and/or estimated print completion time. 